Modular Indoor/Outdoor Synthetic Sports Turf

Abstract

A modular synthetic grass playing surface system formed from a plurality of modular units. Each modular unit has a synthetic grass layer placed upon predetermined sized pallets having a pre-installed elastomeric layer. A layer of resilient particle infill is optionally introduced to the top surface of the modular unit. A corrugated plastic sleeve is optionally installed around each formed modular unit while the modular unit is stored and moved. A plurality of modular units are then installed onto a relatively flat surface to form the playing surface in a desired shape and size.

1 . A synthetic turf sports field comprising: 
 a plurality of modular units coupled together in a desired configuration, each of the modular units comprising:    a modular base structure, wherein said modular base structure comprises a plurality of pallets fastened together in a desired rectangular configuration;    an elastomeric material coupled to a top side of said modular base structure;    a synthetic turf material layer coupled onto said elastomeric material, said synthetic turf material layer comprising a plurality of fibrillated synthetic grass strands tufted into a backing layer, said fibrillated synthetic grass strands having a first pile length extending from said backing layer, said first pile length being between about 0.5 and 2.5 inches;    an optional adhesive layer between said elastomeric material and said synthetic turf material layer; and    a layer of resilient particle infill placed onto said synthetic turf material layer to a first depth, said first depth being less than said first pile length.    
   
   
       2 . The synthetic turf sports field of  claim 1 , wherein said elastomeric layer comprises a rubber based elastomeric layer.  
   
   
       3 . The synthetic turf sports field of  claim 1 , wherein said optional adhesive layer comprises a layer of Nordot 346 adhesive.  
   
   
       4 . The synthetic turf sports field of  claim 1 , wherein said plurality of fibrillated synthetic grass strands comprises a plurality of fibrillated polyethylene grass strands.  
   
   
       5 . The synthetic turf sports field of  claim 1 , wherein said synthetic turf material layer is selected from the group consisting of Thiolon XPS, Thiolon XP and Thiolon LSR.  
   
   
       6 . The synthetic turf sports field of  claim 1 , wherein said synthetic turf material layer is formed utilizing a knit-to-knit process.  
   
   
       7 . The synthetic turf sports field of  claim 1 , wherein said plurality of fibrillated synthetic grass strands has a denier of at least 10000.  
   
   
       8 . The synthetic turf sports field of  claim 1 , wherein said backing material comprises one or more layers of a double woven polypropylene backing material.  
   
   
       9 . The synthetic turf sports field of  claim 1 , wherein said layer of resilient particle infill comprises a layer of cryogenically ground vulcanized rubber infill having an average mesh size of between approximately 8 and 30.  
   
   
       10 . The synthetic turf sports field of  claim 1 , wherein said layer of resilient particle infill comprises a mixture of a layer of cryogenically ground vulcanized rubber infill having an average mesh size of between approximately 8 and 30 and a second resilient material, said second resilient material being selected from the group consisting of ambiently ground rubber, crumb rubber, cork, and polymer beads.  
   
   
       11 . A modular unit used for forming a synthetic turf sports field comprising: 
 a modular base structure, wherein said modular base structure comprises a plurality of pallets fastened together in a desired rectangular configuration;    an elastomeric material coupled to a top side of said modular base structure;    a synthetic turf material layer coupled onto said elastomeric material, said synthetic turf material layer comprising a plurality of fibrillated synthetic grass strands tufted into a backing layer, said fibrillated synthetic grass strands having a first pile length extending from said backing layer, said first pile length being between about 0.5 and 2.5 inches;    an optional adhesive layer between said elastomeric material and said synthetic turf material layer;    a layer of resilient particle infill placed onto said synthetic turf material layer to a first depth, said first depth being less than said first pile length; and    a plastic sleeve coupled around said modular base structure.    
   
   
       12 . The modular unit of  claim 11 , wherein said elastomeric layer comprises a rubber based elastomeric layer.  
   
   
       13 . The modular unit of  claim 11 , wherein said optional adhesive layer comprises a layer of Nordot 346 adhesive.  
   
   
       14 . The modular unit of  claim 11 , wherein said plurality of fibrillated synthetic grass strands comprises a plurality of fibrillated polyethylene grass strands.  
   
   
       15 . The modular unit of  claim 11 , wherein said synthetic turf material layer is selected from the group consisting of Thiolon XPS, Thiolon XP and Thiolon LSR.  
   
   
       16 . The modular unit of  claim 11 , wherein said synthetic turf material layer is formed utilizing a knit-to-knit process.  
   
   
       17 . The modular unit of  claim 11 , wherein said plurality of fibrillated synthetic grass strands has a denier of at least 10000.  
   
   
       18 . The modular unit of  claim 11 , wherein said backing material comprises one or more layers of a double woven polypropylene backing material.  
   
   
       19 . The modular unit of  claim 11 , wherein said layer of resilient particle infill comprises a layer of cryogenically ground vulcanized rubber infill having an average mesh size of between approximately 8 and 30.  
   
   
       20 . The modular unit of  claim 11 , wherein said layer of resilient particle infill comprises a mixture of a layer of cryogenically ground vulcanized rubber infill having an average mesh size of between approximately 8 and 30 and a second resilient material, said second resilient material being selected from the group consisting of ambiently ground rubber, crumb rubber, cork, and polymer beads.